Case Study | June 2022
MerakiPoint enabled Plant Analytics at a manufacturer to gain full visibility in its Plant Operations.
MerakiPoint created a Cloud Data Foundation and Analytics Solution for time-series plant sensor data from Honeywell and Yokogawa DCS systems for all the plants at an integrated manufacturing site. The solution provided higher visibility in plant operations at all levels and increased plant efficiency by 10-15%.
Background
Our client is a Manufacturer of Paper, Pulp and Compostable Tableware products. They had implemented Honeywell and Yokogawa DCS systems for control and automaton of their plants. This data resides in a close architecture and non-availability and non-visibility of this data outside plant floors. The client were looking for end-to-end visibility of all inter-dependent plants, monitoring of key parameters and real-time metrics like Contribution/Hr, Ash Content.
Key Challenges
Close Data Systems: The plant data in Honeywell and Yokogawa DCS systems are highly secured and not-available outside of its network.
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Real-time Metrics Calculation: Certain metrics require inputs from SAP systems along with real-time consumption data from plants.
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Scalability: The scale of data captured and stored became huge. More than 1000 data series, data captured at every 5-10 secs.
Our Solution
MerakiPoint developed a Cloud Data Foundation and Analytics Solution for time-series plant sensor data.
The team provided the technical solution to the most complex problem of data availability outside the closed network of Honeywell and Yokogawa DCS systems.
The team also performed Data Engineering and provided a cost-efficient, scalable solution to ingest and store vast amount of time-series data.
Anytime and anywhere availability of real-time plant dashboards on mobile devices. Real-time Plant dashboards on big TV screens on plant floors.
Tech Stack
\ IOT \ SAP \ InfluxDB \ Grafana
Value Delivered
Anytime and Anywhere visibility of Plant operations outside plant floor increased better control and monitoring.
Real-time Dashboards on Plant floors showing relevant metrics helped operators adjust key parameters.
Overall Plant Efficiency increased by 10-15%.
